Engine oil lubricant compostions and methods for making same with superior oil consumption

ABSTRACT

Provided is an engine oil lubricant composition with improved fuel economy. The engine oil lubricant composition may include about 40 wt % to about 80 wt % of a first oil base stock consisting of a Group IV base oil and about 10 wt % to about 40 wt % of a second oil base stock that is not a Group IV base oil, where these weight percents are based on the total weight of the engine oil lubricant composition. The engine oil lubricant composition can have an HTHS (ASTM D4683) of less than or equal to 2.2 cP at 150° C., a Noack volatility (ASTM D5800) of 25% or less, and an evaporation rate of 6% or less as measured by distillation method DIN 51454 mod. C17-C19.

FIELD OF THE INVENTION

Embodiments of the present invention generally relate to low viscosity engine oil lubricant compositions and methods for making same. Such compostions are useful for gasoline and diesel engines and provide a combination of excellent engine wear protection, corrosion protection and fuel efficiency.

DESCRIPTION OF THE RELATED ART

A major challenge in engine oil formulation is simultaneously achieving engine wear protection while also maintaining fuel economy performance. Fuel efficiency requirements for passenger vehicles are becoming increasingly more stringent. New legislation in the United States and European Union within the past few years has set fuel economy and carbon emissions targets not readily achievable with today's vehicle and lubricant technology. Due to these more stringent governmental regulations for vehicle fuel consumption and carbon emissions, use of low viscosity engine oils to meet these regulatory standards is becoming more prevalent.

To meet future carbon dioxide (CO₂) emission requirements, engine oil formulations often contain organic friction modifiers to help reduce friction and optimize engine efficiency. A major challenge in engine oil formulations containing organic friction modifiers, however, is the high surface activity which can lead to high corrosion.

Another major challenge in engine oil formulations due to the increased use of low viscosity engine oils is engine wear control. Lubricants need to provide a substantial level of durability performance at the same time as wear protection to engine parts due to the formation of thinner lubricant films during engine operation.

High temperature high-shear (HTHS) viscosity is the measure of a lubricant's viscosity under severe engine conditions. Under high temperatures and high stress conditions viscosity index improver degradation can occur. As this happens, the viscosity of the oil decreases which may lead to increased engine wear. HTHS is measured using ASTM D4683, which is incorporated herein by reference. Present day lubricant oils with a high temperature high-shear (HTHS) viscosity of less than 2.9 cP at 150° C. would not be expected to be able to provide acceptable passenger vehicle diesel engine wear and durability performance.

There remains a need for an engine oil lubricant that effectively improves fuel economy while also providing superior engine antiwear performance and anti-corrosion protection.

SUMMARY OF THE INVENTION

Provided is an engine oil lubricant composition with improved fuel economy having an HTHS (ASTM D4683) of less than or equal to 2.2 cP at 150° C., a Noack volatility (ASTM D5800) of 25% or less, and an evaporation rate of 6% or less as measured by distillation method DIN 51454 mod. C17-C19. The engine oil lubricant composition can include about 40 wt % to about 80 wt % of a first oil base stock consisting of a Group IV base oil and about 10 wt % to about 40 wt % of a second oil base stock that is not a Group IV base oil, where these weight percents are based on the total weight of the engine oil lubricant composition.

In another embodiment, the engine oil lubricant composition can include about 40 wt % to about 80 wt % of a first oil base stock consisting of a Group IV base oil, and about 10 wt % to about 40 wt % of a second oil base stock comprising a Group II base oil, where the weight percents are based on the total weight of the engine oil lubricant composition.

In yet another embodiment, the engine oil lubricant composition can include about 40 wt % to about 80 wt % of a first oil base stock consisting of a Group IV base oil, about 10 wt % to about 40 wt % of a second oil base stock comprising a Group II base oil, where the weight percents are based on the total weight of the engine oil lubricant composition, and at least 5 wt % of a third base oil stock comprising a Group V base stock that has a kinematic viscosity at 100° C. of from 2 to 6 cSt.

Any of the foregoing engine oil lubricant compositions may further include one or more anti-wear additives, other viscosity modifiers, antioxidants, detergents, other dispersants, pour point depressants, corrosion inhibitors, metal deactivators, seal compatibility additives, anti-foam agents, inhibitors, anti-rust additives, or any one or more combinations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graphical representation showing the evaporation rate versus Noack volatility of certain engine oil lubricants compositions, according to one or more embodiments provided herein.

FIG. 2 is a graphical representation showing the oil consumption-Noack volatility relationship from engine tests using certain engine oil lubricants compositions, according to one or more embodiments provided herein.

DETAILED DESCRIPTION

A detailed description will now be provided. Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references to the “invention” may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the “invention” will refer to subject matter recited in one or more, but not necessarily all, of the claims. Each of the inventions will now be described in greater detail below, including specific embodiments, versions and examples, but the inventions are not limited to these embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the inventions, when the information in this disclosure is combined with publicly available information and technology.

Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities can refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Furthermore, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.”

The term “or” is intended to encompass both exclusive and inclusive cases, i.e., “A or B” is intended to be synonymous with “at least one of A and B,” unless otherwise expressly specified herein.

The indefinite articles “a” and “an” refer to both singular forms (i.e., “one”) and plural referents (i.e., one or more) unless the context clearly dictates otherwise.

The phrase “consisting essentially of” means that the described/claimed composition does not include any other components that will materially alter its properties by any more than 5% of that property, and in any case, does not include any other component to a level greater than 3 wt %.

Low viscosity engine oil lubricant compositions are provided that show significantly improved fuel efficiency and engine wear protection combined with low oil consumption over a broad range of temperatures. In general it is known that reducing the base oil viscosity in a formulated engine oil while maintaining a constant HTHS viscosity will provide a fuel efficiency benefit.

However, as base oil viscosity is reduced, the base oil molecular weight is also reduced. This can result in increased volatility. ASTM D5800 Noack volatility is often used to measure the volatility characteristics of a formulated engine oil. Simulated distillation DIN 51454 mod. C17-C19 is another test to measure engine oil volatility. It was surprising and unexpectedly discovered that the addition of a low viscosity and low volatility base oil to conventional engine oil lubricant formulations significantly improves fuel efficiency and oil consumption. Such engine oil lubricant compositions exhibit unexpectedly low evaporation rate in comparison to conventional base oil combinations with similar Noack levels.

The engine oil lubricant compositions are non-Newtonian in terms of viscometric properties. A non-Newtonian fluid is a fluid in which the viscous stresses arising from its flow, at every point, are not linearly proportional to the local strain rate. For a non-Newtonian fluid, the viscosity (the measure of a fluid's ability to resist gradual deformation by shear or tensile stresses) is dependent on shear rate or shear rate history. By contrast, a Newtonian fluid is a fluid that in which the viscous stresses arising from its flow, at every point, are linearly proportional to the local strain rate, that is the rate of change of its deformation over time.

The improved engine oil lubricant compositions have low viscosity as measured by kinematic viscosity at 100° C. (ASTM D445, KV100) in having a KV100 of less than or equal to 10 cSt, or less than or equal to 8 cSt, or less than or equal to 6 cSt, or less than or equal to 4 cSt, or less than or equal to 2 cSt. The engine oil lubricant composition also has an HTHS (ASTM D4683) of less than or equal to 2.2 cP at 150° C., or less than or equal to 2.0 cP at 150° C., or less than or equal to 1.8 cP at 150° C., or less than equal to 1.7 cP at 150° C. The HTHS at 150° C. is a measure of fuel efficiency with lower HTHS values yielding improved fuel economy in direct injection engines, gasoline engines, and diesel engines.

The improved engine oil lubricant compositions also have low volatility. In certain embodiments, the improved engine oil lubricant compositions can have a Noack volatility (%), as measured according to ASTM D5800, of less than 25%, less than 20%, less than 15%, less than 12%, less than 10%, less than 8%, or less than 5%.

The engine oil lubricant composition may be used to lubricate internal combustion engines, including, but not limited to, direct injection engines, gasoline engines, and diesel engines. The engine oil lubricant compositions are particularly suitable as OW-4, OW-8, OW-12 and OW-16 viscosity grade engine oils.

Base Oils

Lubricating base oils (or oil base stocks) that are useful in the present disclosure are both natural oils, and synthetic oils, and unconventional oils (or mixtures thereof) can be used unrefined, refined, or rerefined (the latter is also known as reclaimed or reprocessed oil). Unrefined oils are those obtained directly from a natural or synthetic source and used without added purification. These include shale oil obtained directly from retorting operations, petroleum oil obtained directly from primary distillation, and ester oil obtained directly from an esterification process. Refined oils are similar to the oils discussed for unrefined oils except refined oils are subjected to one or more purification steps to improve at least one lubricating oil property. One skilled in the art is familiar with many purification processes. These processes include solvent extraction, secondary distillation, acid extraction, base extraction, filtration, and percolation. Rerefined oils are obtained by processes analogous to refined oils but using an oil that has been previously used.

Groups I, II, III, IV and V are broad categories of base oil stocks developed and defined by the American Petroleum Institute (API Publication 1509; www.API.org) to create guidelines for lubricant base oils. Group I base stocks generally have a viscosity index of between about 80 to 120 and contain greater than about 0.03% sulfur and/or less than about 90% saturates. Group II base stocks generally have a viscosity index of between about 80 to 120, and contain less than or equal to about 0.03% sulfur and greater than or equal to about 90% saturates. Group III stocks generally have a viscosity index greater than about 120 and contain less than or equal to about 0.03% sulfur and greater than about 90% saturates. Group IV includes polyalphaolefins (PAO). Group V base stock includes base stocks not included in Groups I-IV.

Non-limiting exemplary Group V base stocks include alkylated naphthalene base stock, ester base stock, aliphatic ether base stock, aryl ether base stock, ionic liquid base stock, and combinations thereof.

The table below summarizes properties of each of these five groups.

Base Oil Properties

Saturates Sulfur Viscosity Index Group I <90 &/or  >0.03% & ≥80 & <120 Group II ≥90 & ≤0.03% & ≥80 & <120 Group III ≥90 & ≤0.03% & ≥120 Group IV Includes polyalphaolefins (PAO) Group V All other base oil stocks not included in Groups I, II, III, or IV

Natural oils include animal oils, vegetable oils (castor oil and lard oil, for example), and mineral oils. Animal and vegetable oils possessing favorable thermal oxidative stability can be used. Of the natural oils, mineral oils are preferred. Mineral oils vary widely as to their crude source, for example, as to whether they are paraffinic, naphthenic, or mixed paraffinic-naphthenic. Oils derived from coal or shale are also useful. Natural oils vary also as to the method used for their production and purification, for example, their distillation range and whether they are straight run or cracked, hydrorefined, or solvent extracted.

Group II and/or Group III hydroprocessed or hydrocracked basestocks, including synthetic oils such as polyalphaolefins, alkyl aromatics and synthetic esters are also well known oil base stocks.

Synthetic oils include hydrocarbon oil. Hydrocarbon oils include oils such as polymerized and interpolymerized olefins (polybutylenes, polypropylenes, propylene isobutylene copolymers, ethylene-olefin copolymers, and ethylene-alphaolefin copolymers, for example). Polyalphaolefin (PAO) oil base stocks are commonly used synthetic hydrocarbon oil. By way of example, PAOs derived from C₈, C₁₀, C₁₂, C₁₄ olefins or mixtures thereof may be utilized. See U.S. Pat. Nos. 4,956,122; 4,827,064; and 4,827,073.

The number average molecular weights of the PAOs, which are known materials and generally available on a major commercial scale from suppliers such as ExxonMobil Chemical Company, Chevron Phillips Chemical Company, BP, and others, typically vary from about 250 to about 3,000, although PAO's may be made in viscosities up to about 100 cSt (100° C.). The PAOs are typically comprised of relatively low molecular weight hydrogenated polymers or oligomers of alphaolefins which include, but are not limited to, C2 to about C32 alphaolefins with the Cg to about C16 alphaolefins, such as 1-octene, 1-decene, 1-dodecene and the like, being preferred. The preferred polyalphaolefins are poly-1-octene, poly-1-decene and poly-1-dodecene and mixtures thereof and mixed olefin-derived polyolefins. However, the dimers of higher olefins in the range of C₁₄ to C₁₈ may be used to provide low viscosity basestocks of acceptably low volatility. Depending on the viscosity grade and the starting oligomer, the PAOs may be predominantly trimers and tetramers of the starting olefins, with minor amounts of the higher oligomers, having a viscosity range of 1.5 to 12 cSt.

The PAO fluids may be conveniently made by the polymerization of an alphaolefin in the presence of a polymerization catalyst such as the Friedel-Crafts catalysts including, for example, aluminum trichloride, boron trifluoride or complexes of boron trifluoride with water, alcohols such as ethanol, propanol or butanol, carboxylic acids or esters such as ethyl acetate or ethyl propionate. For example the methods disclosed by U.S. Pat. Nos. 4,149,178 or 3,382,291 may be conveniently used herein. Other descriptions of PAO synthesis are found in the following U.S. Pat. Nos. 3,742,082; 3,769,363; 3,876,720; 4,239,930; 4,367,352; 4,413,156; 4,434,408; 4,910,355; 4,956,122; and 5,068,487. The dimers of the C₁₄ to C₁₈ olefins are described in U.S. Pat. No. 4,218,330.

The hydrocarbyl aromatics can be used as base oil or base oil component and can be any hydrocarbyl molecule that contains at least about 5% of its weight derived from an aromatic moiety such as a benzenoid moiety or naphthenoid moiety, or their derivatives. These hydrocarbyl aromatics include alkyl benzenes, alkyl naphthalenes, alkyl diphenyl oxides, alkyl naphthols, alkyl diphenyl sulfides, alkylated bis-phenol A, alkylated thiodiphenol, and the like. The aromatic can be mono-alkylated, dialkylated, polyalkylated, and the like. The aromatic can be mono- or poly-functionalized. The hydrocarbyl groups can also be comprised of mixtures of alkyl groups, alkenyl groups, alkynyl, cycloalkyl groups, cycloalkenyl groups and other related hydrocarbyl groups. The hydrocarbyl groups can range from about C₆ up to about C₆₀ with a range of about C₈ to about C₂₀ often being preferred. A mixture of hydrocarbyl groups is often preferred, and up to about three such substituents may be present. The hydrocarbyl group can optionally contain sulfur, oxygen, and/or nitrogen containing substituents. The aromatic group can also be derived from natural (petroleum) sources, provided at least about 5% of the molecule is comprised of an above-type aromatic moiety. Viscosities at 100° C. of approximately 3 cSt to about 50 cSt are preferred, with viscosities of approximately 3.4 cSt to about 20 cSt often being more preferred for the hydrocarbyl aromatic component. In one embodiment, an alkyl naphthalene where the alkyl group is primarily comprised of 1-hexadecene is used. Other alkylates of aromatics can be advantageously used. Naphthalene or methyl naphthalene, for example, can be alkylated with olefins such as octene, decene, dodecene, tetradecene or higher, mixtures of similar olefins, and the like. Useful concentrations of hydrocarbyl aromatic in a lubricant oil composition can be about 2% to about 25%, preferably about 4% to about 20%, and more preferably about 4% to about 15%, depending on the application.

Esters comprise a useful oil base stock. Additive solvency and seal compatibility characteristics may be secured by the use of esters such as the esters of dibasic acids with monoalkanols and the polyol esters of monocarboxylic acids. Esters of the former type include, for example, the esters of dicarboxylic acids such as phthalic acid, succinic acid, alkyl succinic acid, alkenyl succinic acid, maleic acid, azelaic acid, suberic acid, sebacic acid, fumaric acid, adipic acid, linoleic acid dimer, malonic acid, alkyl malonic acid, alkenyl malonic acid, etc., with a variety of alcohols such as butyl alcohol, hexyl alcohol, dodecyl alcohol, 2-ethylhexyl alcohol, etc. Specific examples of these types of esters include dibutyl adipate, di(2-ethylhexyl) sebacate, di-n-hexyl fumarate, dioctyl sebacate, diisooctyl azelate, diisodecyl azelate, dioctyl phthalate, didecyl phthalate, dieicosyl sebacate, etc.

Particularly useful synthetic esters are those which are obtained by reacting one or more polyhydric alcohols, preferably the hindered polyols (such as the neopentyl polyols, e.g., neopentyl glycol, trimethylol ethane, 2-methyl-2-propyl-1,3-propanediol, trimethylol propane, pentaerythritol and dipentaerythritol) with alkanoic acids containing at least about 4 carbon atoms, preferably C₅ to C₃₀ acids such as saturated straight chain fatty acids including caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachic acid, and behenic acid, or the corresponding branched chain fatty acids or unsaturated fatty acids such as oleic acid, or mixtures of any of these materials.

Suitable synthetic ester components include the esters of trimethylol propane, trimethylol butane, trimethylol ethane, pentaerythritol and/or dipentaerythritol with one or more monocarboxylic acids containing from about 5 to about 10 carbon atoms. These esters are widely available commercially, for example, the Mobil P-41 and P-51 esters of ExxonMobil Chemical Company).

Other useful fluids of lubricating viscosity include non-conventional or unconventional base stocks that have been processed, preferably catalytically, or synthesized to provide high performance lubrication characteristics.

Non-conventional or unconventional base stocks/base oils include one or more of a mixture of base stock(s) derived from one or more Gas-to-Liquids (GTL) materials, as well as isomerate/isodewaxate base stock(s) derived from natural wax or waxy feeds, mineral and or non-mineral oil waxy feed stocks such as slack waxes, natural waxes, and waxy stocks such as gas oils, waxy fuels hydrocracker bottoms, waxy raffinate, hydrocrackate, thermal crackates, or other mineral, mineral oil, or even non-petroleum oil derived waxy materials such as waxy materials received from coal liquefaction or shale oil, and mixtures of such base stocks.

The base oil constitutes the major component of the engine oil lubricant composition of the present invention and typically is present in an amount ranging from about 50 to about 99 wt %, e.g., from 70 to 90 wt % or from about 85 to about 95 wt %, based on the total weight of the composition. The base oil may be selected from any of the synthetic or natural oils typically used as crankcase lubricating oils for spark-ignited and compression-ignited engines. The base oil conveniently has a kinematic viscosity, according to ASTM standards, of about 1.0 cSt to about 16.0 cSt (or mm²/s) at 100° C., preferably of about 1.0 cSt to about 12.0 cSt (or mm²/s) at 100° C., more preferably of about 2.0 cSt to about 8.0 cSt (or mm²/s) at 100° C. and even more preferably of about 2.0 cSt to about 4.0 cSt (or mm²/s) at 100° C. Mixtures of synthetic and natural base oils may be used if desired. As used herein, the base stock name is associated with the D445 KV100 viscosity of the base stock. For instance, PAO 4 has a D445 100C viscosity of 4 cSt; GTL 3 has a D445 100C viscosity of 3 cSt.

The engine oil lubricant composition of the present invention can have an HTHS viscosity of less than or equal to 2.2 cP at 150° C., or less than or equal to 2.1 cP at 150° C., or less than or equal to 2.0 cP at 150° C., or less than or equal to 1.9 cP at 150° C., and preferably about 2.0 cP at 150° C.

Viscosity Modifiers (VM)

Viscosity modifiers are also known as VI improvers, viscosity index improvers and viscosity improvers. Suitable viscosity modifiers provide lubricants with high temperature and low temperature operability. Suitable viscosity modifiers also impart shear stability at elevated temperatures and acceptable viscosity at low temperatures. Suitable viscosity modifiers may be or may include one or more linear or star-shaped polymers and/or copolymers of methacrylate, butadiene, olefins, isoprene or alkylated styrenes, polyisobutylene, polymethacrylate, ethylene-propylene, hydrogenated block copolymer of styrene and isoprene, polyacrylates, styrene-isoprene block copolymer, styrene-butadiene copolymer, ethylene-propylene copolymer, hydrogenated star polyisoprene, and combinations thereof.

As used herein, the term “polymer” refers to any two or more of the same or different repeating units/mer units or units. The term “homopolymer” refers to a polymer having units that are the same. The term “copolymer” refers to a polymer having two or more units that are different from each other, and includes terpolymers and the like. The term “terpolymer” refers to a polymer having three units that are different from each other. The term “different” refers to units indicates that the units differ from each other by at least one atom or are different isomerically. Likewise, the definition of polymer, as used herein, includes homopolymers, copolymers, and the like. Furthermore, the term “styrenic block copolymer” refers to any copolymer that includes units of styrene and a mid-block.

Suitable olefin copolymers, for example, are commercially available from Chevron Oronite

Company LLC under the trade designation “PARATONE®” (such as “PARATONE® 8921” and “PARATONE® 8941”); from Afton Chemical Corporation under the trade designation “HiTEC®” (such as “HiTEC® 5850B”; and from The Lubrizol Corporation under the trade designation “Lubrizol® 7067C”. Suitable polyisoprene polymers, for example, are commercially available from Infineum International Limited, e.g. under the trade designation “SV200”. Suitable diene-styrene copolymers, for example, are commercially available from Infineum International Limited, e.g. under the trade designation “SV 260”.

One particularly suitable viscosity modifier is polyisobutylene. Another particularly suitable viscosity modifier is polymethacrylate, which can also serve as pour point depressant. Other particularly suitable viscosity modifiers include copolymers of ethylene and propylene, hydrogenated block copolymers of styrene and isoprene, and polyacrylates. Specific examples include styrene-isoprene and styrene-butadiene based polymers of 50,000 to 200,000 molecular weight.

Suitable viscosity modifiers may further include high molecular weight hydrocarbons, polyesters and dispersants that function as both a viscosity modifier and a dispersant. Typical molecular weights of these polymers may range between about 10,000 and about 2,000,000, more typically about 20,000 and about 1,500,000, and even more typically between about 50,000 and about 1,200,000.

The at least one viscosity modifier may be included in the engine oil lubricant composition at a concentration of from 0.1 to 5 wt %, or 0.1 to 8 wt %, or 0.1 to 14 wt %, or 0.5 to 10 wt %, or 0.01 to 2 wt %, or 1.0 to 7.5 wt %, or 1.5 to 5 wt %. The at least one viscosity modifier may also be included in the engine oil lubricant composition at a concentration ranging from a low of about about 0.1 wt %, about 0.3 wt %, or about 0.5 wt % to a high of about 5 wt %, about 8 wt %, or about 16 wt %. The at least one viscosity modifier concentration may also range from a low of about about 0.1 wt %, about 0.5 wt %, or about 1.0 wt % to a high of about 8 wt %, about 12 wt %, or about 14 wt %. The foregoing viscosity modifier concentrations are based on a polymer concentrate basis in terms of the total weight of the lubricating composition.

Friction Modifier

A friction modifier is any material or two or more materials that can alter the coefficient of friction of a surface lubricated by a lubricant or fluid containing such material(s). Friction modifiers, also known as friction reducers, or lubricity agents or oiliness agents, and other such agents that change the ability of base oils, formulated lubricant compositions, or functional fluids, to modify the coefficient of friction of a lubricated surface may be effectively used in combination with the base oils or lubricant compositions of the present invention if desired. Friction modifiers that lower the coefficient of friction are particularly advantageous in combination with the base oils and lube compositions of this invention. Friction modifiers may include metal-containing compounds or materials as well as ashless compounds or materials, or mixtures thereof. Metal-containing friction modifiers may include metal salts or metal-ligand complexes where the metals may include alkali, alkaline earth, or transition group metals. Such metal-containing friction modifiers may also have low-ash characteristics. Transition metals may include Mo, Sb, Sn, Fe, Cu, Zn, and others. Such suitable ligands may include hydrocarbyl derivative of alcohols, polyols, glycerols, partial ester glycerols, thiols, carboxylates, carbamates, thiocarbamates, dithiocarbamates, phosphates, thiophosphates, dithiophosphates, amides, imides, amines, thiazoles, thiadiazoles, dithiazoles, diazoles, triazoles, and other polar molecular functional groups containing effective amounts of O, N, S, or P, individually or in combination.

Ashless friction modifiers can also be used. Suitable ashless friction modifiers may include hydroxyl-containing hydrocarbyl base oils, glycerides, partial glycerides, glyceride derivatives, fatty organic acids, fatty amines, and sulfurized fatty acids. Suitable ashless friction modifiers may also include lubricant materials that contain effective amounts of polar groups, for example, hydroxyl-containing hydrocarbyl base oils, glycerides, partial glycerides, glyceride derivatives, and the like. Polar groups in friction modifiers may include hydrocarbyl groups containing effective amounts of O, N, S, or P, individually or in combination. Other friction modifiers that may be particularly effective include, for example, salts (both ash-containing and ashless derivatives) of fatty acids, fatty alcohols, fatty amides, fatty esters, hydroxyl-containing carboxylates, and comparable synthetic long-chain hydrocarbyl acids, alcohols, amides, esters, hydroxy carboxylates, and the like. In some instances fatty organic acids, fatty amines, and sulfurized fatty acids may be used as suitable friction modifiers. In some instances, friction modifiers containing ethylene-oxide segments are effective.

Ashless friction modifiers may be or may include polymeric and/or non-polymeric molecules. A suitable polymeric friction modifier may have a weight average molecular weight (Mw) of 3,000 or more; 4,000 or more; 5,000 or more; 6,000 or more; 7,000 or more; 8,000 or more; 9,000 or more; 10,000 or more; 15,000 or more; 20,000 or more; 30,000 or more; 40,000 or more; or 45,000 or more. The Mw of suitable polymeric friction modifiers may also range from a low of about 3,000, about 4,000, or about 5,000 to a high of about 10,000; about 30,000, or about 50,000. The Mw of suitable polymeric friction modifiers may also range from about 3,000 to 15,000; about 4,000 to about 12,000; about 3,000 to about 9,000; about 3,000 to about 7,000. The Mw of suitable polymeric friction modifiers may also be about 3,000, about 4,000, about 5,000, about 6,000, about 7,000, about 8,000, or about 9,000. A particularly suitable polymeric friction modifier is or includes ethylene oxide (EtO).

Other Additives

The engine oil lubricant composition may also include one or more other additives typical for engine oils. These other additives may include any one or more anti-wear additives, dispersants, detergents, antioxidants, pour point depressanst, corrosion inhibitors, anti-rust additives, metal deactivators, seal compatibility additives, and anti-foam agents. These other additives may be provided to the lubricant composition in the form of an additive package. The additive packages may be incorporated into the engine lubricant compositions at loadings of about 9 wt % to about 15 wt %, or about 10 to about 14.5 wt %, or about 11 to about 14 wt %, based on the total weight of the composition. The additive packages may also be incorporated into the engine lubricant compositions at loadings ranging from a low of about 5 wt %, about 7 wt %, about 9 wt %, or about 10 wt % to a high of about 11 wt %, about 14 wt %, about 14.5 wt %, or about 15 wt %, based on the total weight of the composition.

Antiwear

While there are many different types of antiwear additives, for several decades the principal antiwear additive for internal combustion engine crankcase oils is a metal alkylthiophosphate and more particularly a metal dialkyldithiophosphate in which the metal constituent is zinc, or zinc dialkyldithiophosphate (ZDDP). ZDDP can be primary, secondary or mixtures thereof. ZDDP compounds generally are of the formula Zn[SP(S)(OR¹)(OR²)]₂ where R¹ and R² are C₁-C₁₈ alkyl groups, preferably C₂-C₁₂ alkyl groups. These alkyl groups may be straight chain or branched. The ZDDP is typically used in amounts of from about 0.4 to 1.4 wt % of the total lubricant oil composition, although more or less can often be used advantageously. Preferably, the ZDDP is a secondary ZDDP and present in an amount of from about 0.6 to 1.0 wt %, or from 0.6 to 0.91 wt % of the total lubricant composition.

Preferable zinc dithiophosphates which are commercially available include secondary zinc dithiophosphates such as those available from for example, The Lubrizol Corporation under the trade designations “LZ 677A”, “LZ 1095” and “LZ 1371”, from for example Chevron Oronite under the trade designation “OLOA 262” and from for example Afton Chemical under the trade designation “HITEC 7169”.

Dispersants

During engine operation, oil-insoluble oxidation byproducts are produced. Dispersants help keep these byproducts in solution, thus diminishing their deposition on metal surfaces.

Dispersants may be ashless or ash-forming in nature. Preferably, the dispersant is ashless. So-called ashless dispersants are organic materials that form substantially no ash upon combustion. For example, non-metal-containing or borated metal-free dispersants are considered ashless. In contrast, metal-containing detergents discussed above form ash upon combustion.

Suitable dispersants typically contain a polar group attached to a relatively high molecular weight hydrocarbon chain. The polar group typically contains at least one element of nitrogen, oxygen, or phosphorus. Typical hydrocarbon chains contain 50 to 400 carbon atoms.

Chemically, many dispersants may be characterized as phenates, sulfonates, sulfurized phenates, salicylates, naphthenates, stearates, carbamates, thiocarbamates, phosphorus derivatives. A particularly useful class of dispersants are the alkenylsuccinic derivatives, typically produced by the reaction of a long chain substituted alkenyl succinic compound, usually a substituted succinic anhydride, with a polyhydroxy or polyamino compound. The long chain group constituting the oleophilic portion of the molecule which confers solubility in the oil, is normally a polyisobutylene group. Many examples of this type of dispersant are well known commercially and in the literature. Exemplary U.S. Patents describing such dispersants are U.S. Pat. Nos. 3,172,892; 3,215,707; 3,219,666; 3,316,177; 3,341,542; 3,444,170; 3,454,607; 3,541,012; 3,630,904; 3,632,511; 3,787,374 and 4,234,435. Other types of dispersant are described in U.S. Pat. Nos. 3,036,003; 3,200,107; 3,254,025; 3,275,554; 3,438,757; 3,454,555; 3,565,804; 3,413,347; 3,697,574; 3,725,277; 3,725,480; 3,726,882; 4,454,059; 3,329,658; 3,449,250; 3,519,565; 3,666,730; 3,687,849; 3,702,300; 4,100,082; 5,705,458. A further description of dispersants may be found, for example, in European Patent Application No. 471 071, to which reference is made for this purpose.

Hydrocarbyl-substituted succinic acid compounds are popular dispersants. In particular, succinimide, succinate esters, or succinate ester amides prepared by the reaction of a hydrocarbon-substituted succinic acid compound preferably having at least 50 carbon atoms in the hydrocarbon substituent, with at least one equivalent of an alkylene amine are particularly useful.

Succinimides are formed by the condensation reaction between alkenyl succinic anhydrides and amines. Molar ratios can vary depending on the polyamine. For example, the molar ratio of alkenyl succinic anhydride to TEPA can vary from about 1:1 to about 5:1. Representative examples are shown in U.S. Pat. Nos. 3,087,936; 3,172,892; 3,219,666; 3,272,746; 3,322,670; and 3,652,616, 3,948,800; and Canada Pat. No. 1,094,044.

Succinate esters are formed by the condensation reaction between alkenyl succinic anhydrides and alcohols or polyols. Molar ratios can vary depending on the alcohol or polyol used. For example, the condensation product of an alkenyl succinic anhydride and pentaerythritol is a useful dispersant.

Succinate ester amides are formed by condensation reaction between alkenyl succinic anhydrides and alkanol amines. For example, suitable alkanol amines include ethoxylated polyalkylpolyamines, propoxylated polyalkylpolyamines and polyalkenylpolyamines such as polyethylene polyamines. One example is propoxylated hexamethylenediamine. Representative examples are shown in U.S. Pat. No. 4,426,305.

The molecular weight of the alkenyl succinic anhydrides used in the preceding paragraphs will typically range between 800 and 2,500. The above products can be post-reacted with various reagents such as sulfur, oxygen, formaldehyde, carboxylic acids such as oleic acid, and boron compounds such as borate esters or highly borated dispersants. The dispersants can be borated with from about 0.1 to about 5 moles of boron per mole of dispersant reaction product.

Mannich base dispersants are made from the reaction of alkylphenols, formaldehyde, and amines. See U.S. Pat. No. 4,767,551, which is incorporated herein by reference. Process aids and catalysts, such as oleic acid and sulfonic acids, can also be part of the reaction mixture. Molecular weights of the alkylphenols range from 800 to 2,500. Representative examples are shown in U.S. Pat. Nos. 3,697,574; 3,703,536; 3,704,308; 3,751,365; 3,756,953; 3,798,165; and 3,803,039.

Typical high molecular weight aliphatic acid modified Mannich condensation products useful in this invention can be prepared from high molecular weight alkyl-substituted hydroxyaromatics or HN(R)₂ group-containing reactants.

Hydrocarbyl substituted amine ashless dispersant additives are well known to one skilled in the art; see, for example, U.S. Pat. Nos. 3,275,554; 3,438,757; 3,565,804; 3,755,433, 3,822,209, and 5,084,197.

Preferred dispersants include borated and non-borated succinimides, including those derivatives from mono-succinimides, bis-succinimides, and/or mixtures of mono- and bis-succinimides, wherein the hydrocarbyl succinimide is derived from a hydrocarbylene group such as polyisobutylene having a Mn of from about 500 to about 5000 or a mixture of such hydrocarbylene groups. Other preferred dispersants include succinic acid-esters and amides, alkylphenol-polyamine-coupled Mannich adducts, their capped derivatives, and other related components. Such additives may be used in an amount of about 0.1 to 20 wt %, preferably about 0.5 to 8 wt %.

Detergents

Detergents are commonly used in lubricating compositions. A typical detergent is an anionic material that contains a long chain hydrophobic portion of the molecule and a smaller anionic or oleophobic hydrophilic portion of the molecule. The anionic portion of the detergent is typically derived from an organic acid such as a sulfur acid, carboxylic acid, phosphorous acid, phenol, or mixtures thereof. The counterion is typically an alkaline earth or alkali metal.

Salts that contain a substantially stochiometric amount of the metal are described as neutral salts and have a total base number (TBN, as measured by ASTM D2896) of from 0 to 80. Many compositions are overbased, containing large amounts of a metal base that is achieved by reacting an excess of a metal compound (a metal hydroxide or oxide, for example) with an acidic gas (such as carbon dioxide). Useful detergents can be neutral, mildly overbased, or highly overbased.

It is desirable for at least some detergent to be overbased. Overbased detergents help neutralize acidic impurities produced by the combustion process and become entrapped in the oil. Typically, the overbased material has a ratio of metallic ion to anionic portion of the detergent of about 1.05:1 to 50:1 on an equivalent basis. More preferably, the ratio is from about 4:1 to about 25:1. The resulting detergent is an overbased detergent that will typically have a TBN of about 150 or higher, often about 250 to 450 or more. Preferably, the overbasing cation is sodium, calcium, or magnesium. A mixture of detergents of differing TBN can be used in the present invention.

Preferred detergents include the alkali or alkaline earth metal salts of sulfonates, phenates, carboxylates, phosphates, and salicylates.

Sulfonates may be prepared from sulfonic acids that are typically obtained by sulfonation of alkyl substituted aromatic hydrocarbons. Hydrocarbon examples include those obtained by alkylating benzene, toluene, xylene, naphthalene, biphenyl and their halogenated derivatives (chlorobenzene, chlorotoluene, and chloronaphthalene, for example). The alkylating agents typically have about 3 to 70 carbon atoms. The alkaryl sulfonates typically contain about 9 to about 80 carbon or more carbon atoms, more typically from about 16 to 60 carbon atoms.

Klamann in “Lubricants and Related Products”, op cit discloses a number of overbased metal salts of various sulfonic acids which are useful as detergents and dispersants in lubricants. The book entitled “Lubricant Additives”, C. V. Smallheer and R. K. Smith, published by the Lezius-Hiles Co. of Cleveland, Ohio (1967), similarly discloses a number of overbased sulfonates that are useful as dispersants/detergents.

Alkaline earth phenates are another useful class of detergent. These detergents can be made by reacting alkaline earth metal hydroxide or oxide (CaO, Ca(OH)₂, BaO, Ba(OH)₂, MgO, Mg(OH)₂, for example) with an alkyl phenol or sulfurized alkylphenol. Useful alkyl groups include straight chain or branched C₁-C₃₀ alkyl groups, preferably, C₄-C₂₀. Examples of suitable phenols include isobutylphenol, 2-ethylhexylphenol, nonylphenol, dodecyl phenol, and the like. It should be noted that starting alkylphenols may contain more than one alkyl substituent that are each independently straight chain or branched. When a non-sulfurized alkylphenol is used, the sulfurized product may be obtained by methods well known in the art. These methods include heating a mixture of alkylphenol and sulfurizing agent (including elemental sulfur, sulfur halides such as sulfur dichloride, and the like) and then reacting the sulfurized phenol with an alkaline earth metal base.

Metal salts of carboxylic acids are also useful as detergents. These carboxylic acid detergents may be prepared by reacting a basic metal compound with at least one carboxylic acid and removing free water from the reaction product. These compounds may be overbased to produce the desired TBN level. Detergents made from salicylic acid are one preferred class of detergents derived from carboxylic acids. Useful salicylates include long chain alkyl salicylates. One useful family of compositions is of the formula

where R is a hydrogen atom or an alkyl group having 1 to about 30 carbon atoms, n is an integer from 1 to 4, and M is an alkaline earth metal. Preferred R groups are alkyl chains of at least C₁₁, preferably C₁₃ or greater. R may be optionally substituted with substituents that do not interfere with the detergent's function. M is preferably, calcium, magnesium, or barium. More preferably, M is calcium.

Hydrocarbyl-substituted salicylic acids may be prepared from phenols by the Kolbe reaction (see U.S. Pat. No. 3,595,791). The metal salts of the hydrocarbyl-substituted salicylic acids may be prepared by double decomposition of a metal salt in a polar solvent such as water or alcohol.

Alkaline earth metal phosphates may also be used as detergents.

Detergents may be simple detergents or what is known as hybrid or complex detergents.

The latter detergents can provide the properties of two detergents without the need to blend separate materials. See U.S. Pat. 6,034,039, for example.

Preferred detergents may include calcium phenates, calcium sulfonates, calcium salicylates, magnesium phenates, magnesium sulfonates, magnesium salicylates and other related components (including borated detergents). Typically, the total detergent concentration is about 0.01 to about 6.0 wt %, or 0.01 to 4 wt %, or 0.01 to 3 wt %, or 0.01 to 2.2 wt %, or 0.01 to 1.5 wt % and preferably, about 0.1 to 3.5 wt %.

Antioxidants

Antioxidants retard the oxidative degradation of base oils during service. Such degradation may result in deposits on metal surfaces, the presence of sludge, or a viscosity increase in the lubricant.

One skilled in the art knows a wide variety of oxidation inhibitors that are useful in lubricating oil compositions. See, Klamann in Lubricants and Related Products, op cite, and U.S. Pat. Nos. 4,798,684 and 5,084,197, for example.

Useful antioxidants may include hindered phenols. These phenolic antioxidants may be ashless (metal-free) phenolic compounds or neutral or basic metal salts of certain phenolic compounds.

Typical phenolic antioxidant compounds are the hindered phenolics which are the ones which contain a sterically hindered hydroxyl group, and these include those derivatives of dihydroxy aryl compounds in which the hydroxyl groups are in the o- or p-position to each other. Typical phenolic antioxidants include the hindered phenols substituted with C6+ alkyl groups and the alkylene coupled derivatives of these hindered phenols. Examples of phenolic materials of this type 2-t-butyl-4-heptyl phenol; 2-t-butyl-4-octyl phenol; 2-t-butyl-4-dodecyl phenol; 2,6-di-t-butyl-4-heptyl phenol; 2,6-di-t-butyl-4-dodecyl phenol; 2-methyl-6-t-butyl-4-heptyl phenol; and 2-methyl-6-t-butyl-4-dodecyl phenol.

Other useful hindered mono-phenolic antioxidants may include for example hindered 2,6-di-alkyl-phenolic proprionic ester derivatives. Bis-phenolic antioxidants may also be advantageously used in combination with the instant invention. Examples of ortho-coupled phenols include: 2,2′-bis(4-heptyl-6-t-butyl-phenol); 2,2′-bis(4-octyl-6-t-butyl-phenol); and 2,2′-bis(4-dodecyl-6-t-butyl-phenol). Para-coupled bisphenols include for example 4,4′-bis(2,6-di-t-butyl phenol) and 4,4′-methylene-bis(2,6-di-t-butyl phenol).

Non-phenolic oxidation inhibitors which may be used include aromatic amine antioxidants and these may be used either as such or in combination with phenolics. Typical examples of non-phenolic antioxidants include: alkylated and non-alkylated aromatic amines such as aromatic monoamines of the formula R⁸R⁹R¹⁰N where R⁸ is an aliphatic, aromatic or substituted aromatic group, R⁹ is an aromatic or a substituted aromatic group, and R¹⁰ is H, alkyl, aryl or R¹¹S(O)_(x)R¹² where R¹¹ is an alkylene, alkenylene, or aralkylene group, R¹² is a higher alkyl group, or an alkenyl, aryl, or alkaryl group, and x is 0, 1 or 2. The aliphatic group R⁸ may contain from 1 to about 20 carbon atoms, and preferably contains from about 6 to 12 carbon atoms. The aliphatic group is a saturated aliphatic group. Preferably, both R⁸ and R⁹ are aromatic or substituted aromatic groups, and the aromatic group may be a fused ring aromatic group such as naphthyl. Aromatic groups R⁸ and R⁹ may be joined together with other groups such as S.

Typical aromatic amines antioxidants have alkyl substituent groups of at least about 6 carbon atoms. Examples of aliphatic groups include hexyl, heptyl, octyl, nonyl, and decyl. Generally, the aliphatic groups will not contain more than about 14 carbon atoms. The general types of amine antioxidants useful in the present compositions include diphenylamines, phenyl naphthylamines, phenothiazines, imidodibenzyls and diphenyl phenylene diamines. Mixtures of two or more aromatic amines are also useful. Polymeric amine antioxidants can also be used. Particular examples of aromatic amine antioxidants useful in the present invention include: p,p′-dioctyldiphenylamine; t-octylphenyl-alpha-naphthylamine; phenyl-alphanaphthylamine; and p-octylphenyl-alpha-naphthylamine. Sulfurized alkyl phenols and alkali or alkaline earth metal salts thereof may also be useful antioxidants.

Preferred antioxidants include hindered phenols, arylamines. These antioxidants may be used individually by type or in combination with one another.

Antioxidants may be used in an amount of about 0.01 to 5 wt %, preferably about 0.01 to 1.5 wt %, more preferably zero to less than 1.5 wt %, most preferably zero, based on the total weight of the engine oil lubricant.

Pour Point Depressants

Conventional pour point depressants (also known as lube oil flow improvers) may be added to the compositions of the present invention if desired. These pour point depressant may be added to lubricating compositions of the present invention to lower the minimum temperature at which the fluid will flow or can be poured. Examples of suitable pour point depressants include polymethacrylates, polyacrylates, polyarylamides, condensation products of haloparaffin waxes and aromatic compounds, vinyl carboxylate polymers, and terpolymers of dialkylfumarates, vinyl esters of fatty acids and allyl vinyl ethers. U.S. Pat. Nos. 1,815,022; 2,015,748; 2,191,498; 2,387,501; 2,655,479; 2,666,746; 2,721,877; 2,721,878; and 3,250,715 describe useful pour point depressants and/or the preparation thereof. Such additives may be used in an amount of about 0.01 to 5 wt %, preferably about 0.01 to 1.5 wt %, based on the total weight of the engine oil lubricant.

Corrosion Inhibitor

One or more corrosion inhibitors may be added to the lubricating oil compositions.

Corrosion inhibitors are additives that protect lubricated metal surfaces against chemical attack by water or other contaminants. Corrosion inhibitors may also be used to reduce the degradation of metallic parts that are in contact with the lubricating oil composition. As used herein, corrosion inhibitors include anti-rust additives, metal deactivators, and metal passivators.

One type of corrosion inhibitor is a polar compound that wets the metal surface preferentially, protecting it with a film of oil. Another type of corrosion inhibitor absorbs water by incorporating it in a water-in-oil emulsion so that only oil touches the metal surface. Yet another type of corrosion inhibitor chemically adheres to the metal to produce a non-reactive surface. Suitable corrosion inhibitors include zinc dithiophosphates, metal phenolates, basic metal sulfonates, fatty acids and amines. Other suitable corrosion inhibitors include, for example, aryl thiazines, alkyl substituted dimercaptothiodiazoles, alkyl substituted dimercaptothiadiazoles, thiazoles, triazoles, non-ionic polyoxyalkylene polyols and esters thereof, polyoxyalkylene phenols, anionic alkyl sulfonic acids, and the like, and mixtures thereof.

Illustrative corrosion inhibitors may include, for example, (short-chain) alkenyl succinic acids, partial esters thereof and nitrogen-containing derivatives thereof; and petroleum sulfonates, synthetic sulfonates, synthetic alkarylsulfonates, such as metal alkylbenzene sulfonates, and metal dinonylnaphthalene sulfonates. Corrosion inhibitors also include, for example, monocarboxylic acids which have from 8 to 30 carbon atoms, alkyl or alkenyl succinates or partial esters thereof, hydroxy-fatty acids which have from 12 to 30 carbon atoms and derivatives thereof, sarcosines which have from 8 to 24 carbon atoms and derivatives thereof, amino acids and derivatives thereof, naphthenic acid and derivatives thereof, lanolin fatty acid, mercapto-fatty acids and paraffin oxides.

Particularly preferred corrosion inhibitors include, for example, monocarboxylic acids (C₈-C₃₀), caprylic acid, pelargonic acid, decanoic acid, undecanoic acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachic acid, behenic acid, cerotic acid, montanic acid, melissic acid, oleic acid, docosanic acid, erucic acid, eicosenic acid, beef tallow fatty acid, soy bean fatty acid, coconut oil fatty acid, linolic acid, linoleic acid, tall oil fatty acid, 12-hydroxystearic acid, laurylsarcosinic acid, myritsylsarcosinic acid, palmitylsarcosinic acid, stearylsarcosinic acid, oleylsarcosinic acid, alkylated (C₈-C₂₀) phenoxyacetic acids, lanolin fatty acid and C₈-C₂₄ mercapto-fatty acids.

Examples of polybasic carboxylic acids which function as corrosion inhibitors include alkenyl (C₁₀-C₁₀₀) succinic acids and ester derivatives thereof, dimer acid, N-acyl-N-alkyloxyalkyl aspartic acid esters (U.S. Pat. No. 5,275,749). Examples of the alkylamines which function as corrosion inhibitors or as reaction products with the above carboxylates to give amides and the like are represented by primary amines such as laurylamine, coconut-amine, n-tridecylamine, myristylamine, n-pentadecylamine, palmitylamine, n-heptadecylamine, stearylamine, n-nonadecylamine, n-eicosylamine, n-heneicosylamine, n-docosylamine, n-tricosylamine, n-pentacosylamine, oleylamine, beef tallow-amine, hydrogenated beef tallow-amine and soy bean-amine. Examples of the secondary amines include dilaurylamine, di-coconut-amine, di-n-tri decyl amine, dimyristylamine, di-n-pentadecylamine, dipalmitylamine, di-n-pentadecylamine, di stearylamine, di-n-nonadecylamine, di-n-eicosylamine, di-n-heneicosylamine, di-n-docosylamine, di-n-tricosylamine, di-n-pentacosyl-amine, dioleylamine, di-beef tallow-amine, di-hydrogenated beef tallow-amine and di-soy bean-amine. Examples of the aforementioned alkylenediamines, alkylated alkylenediamines, and N-alkylpolyalkyenediamines include: ethylenediamines such as laurylethylenediamine, coconut ethylenediamine, n-tridecyl ethyl enediamine-, myri styl ethyl enediamine, n-pentadecyl ethylenediamine, palmitylethylenediamine, n-heptadecylethylenediamine, stearylethylenediamine, n-nonadecylethylenediamine, n-eicosylethylenediamine, n-heneicosylethylenediamine, n-docosylethylendiamine, n-tricosylethylenediamine, n-pentacosylethylenediamine, oleylethylenediamine, beef tallow-ethylenediamine, hydrogenated beef tallow-ethylenediamine and soy bean-ethylenediamine; propylenediamines such as laurylpropylenediamine, coconut propyl enediamine, n-tridecylpropylenediamine, myristylpropylenediamine, n-pentadecylpropylenediamine, palmitylpropylenediamine, n-heptadecylpropylenediamine, stearylpropylenediamine, n-nonadecylpropylenediamine, n-eicosylpropylenediamine, n-heneicosylpropylenediamine, n-docosylpropylendiamine, n-tricosylpropylenediamine, n-pentacosylpropylenediamine, diethylene triamine (DETA) or triethylene tetramine (TETA), oleylpropylenediamine, beef tallow-propylenediamine, hydrogenated beef tallow-propylenediamine and soy bean-propylenediamine; butylenediamines such as laurylbutylenediamine, coconut butylenediamine, n-tridecylbutylenediamine-myristylbutylenediamine, n-pentadecylbutylenediamine, stearylbutylenediamine, n-eicosylbutylenedi amine, n-heneicosylbutylenedia-mine, n-docosylbutylendiamine, n-tricosylbutylenediamine, n-pentacosylbutylenediamine, oleylbutylenediamine, beef tallow-butylenediamine, hydrogenated beef tallow-butylenediamine and soy bean butylenediamine; and pentylenediamines such as laurylpentyl enediamine, coconut pentylenediamine, myristylpentylenediamine, palmitylpentylenediamine, stearylpentylenediamine, oleyl-pentylenediamine, beef tallow-pentylenediamine, hydrogenated beef tallow-pentylenediamine and soy bean pentylenediamine.

Other illustrative corrosion inhibitors include 2,5-dimercapto-1,3,4-thiadiazoles and derivatives thereof, mercaptobenzothiazoles, alkyltriazoles and benzotriazoles. Examples of dibasic acids useful as corrosion inhibitors, which are used in the present disclosure, are sebacic acid, adipic acid, azelaic acid, dodecanedioic acid, 3-methyladipic acid, 3-nitrophthalic acid, 1,10-decanedicarboxylic acid, and fumaric acid. The corrosion inhibitors may be a straight or branch-chained, saturated or unsaturated monocarboxylic acid or ester thereof which are optionally sulfurized in an amount up to 35 wt %. Preferably the acid is a C₄ to C₂₂ straight chain unsaturated monocarboxylic acid. The preferred concentration of this additive is from 0.001 wt % to 0.35 wt % of the total lubricant composition. The preferred monocarboxylic acid is sulfurized oleic acid. Alternatively, other suitable materials include oleic acid itself, valeric acid and erucic acid. An illustrative corrosion inhibitor includes a triazole as previously defined. The triazole should be used at a concentration from 0.005 wt % to 0.25 wt % of the total composition. The preferred triazole is tolylotriazole which is suitably included in the compositions of the disclosure. Also suitably included in compositions are triazoles, thiazoles and certain diamine compounds which are useful as metal deactivators or metal passivators. Examples include triazole, benzotriazole and substituted benzotriazoles such as alkyl substituted derivatives. The alkyl substituent generally contains up to 15 carbon atoms, preferably up to 8 carbon atoms. The triazoles optionally contain other substituents on the aromatic ring such as halogens, nitro, amino, mercapto, etc. Examples of suitable compounds are benzotriazole and the tolyltriazoles, ethylbenzotriazoles, hexylbenzotriazoles, octylbenzotriazoles, chlorobenzotriazoles and nitrobenzotriazoles. Benzotriazole and tolyltriazole are particularly preferred. A straight or branched chain saturated or unsaturated monocarboxylic acid which is optionally sulfurized in an amount which is up to 35 wt %; or an ester of such an acid; and a triazole or alkyl derivatives thereof, or short chain alkyl of up to 5 carbon atoms; n is zero or an integer between 1 and 3 inclusive; and is hydrogen, morpholino, alkyl, amido, amino, hydroxy or alkyl or aryl substituted derivatives thereof; or a triazole selected from 1,2,4 triazole, 1,2,3 triazole, 5-anilo-1,2,3,4-thiatriazole, 3-amino-1,2,4 triazole, 1-H-benzotriazole-1-yl-methylisocyanide, methylene-bis-benzotriazole and naphthotriazole.

Other illustrative corrosion inhibitors may include 2-mercaptobenzothiazole, dialkyl-2,5-dimercapto-1,3,4-thiadiazole; N,N′-di salicylideneethyl enediamine, N,N′-disalicylidenepropylenediamine, N-salicylideneethyl amine, N,N′-di salicylideneethyldiamine; triethylenediamine, ethylenediaminetetraacetic acid; zinc dialkyldithiophosphates and dialkyl dithiocarbamates, and the like.

Other illustrative corrosion inhibitors may include a yellow metal passivator. The term “yellow metal” refers to a metallurgical grouping that includes, for example, brass and bronze alloys, aluminum bronze, phosphor bronze, copper, copper nickel alloys, and beryllium copper, and the like.

Typical yellow metal passivators include, for example, benzotriazole, tolutriazole, tolyltriazole, mixtures of sodium tolutriazole and tolyltriazole, imidazole, benzimidazole, imidazoline, pyrimidine, and derivatives thereof, and combinations thereof. In one particular and non-limiting embodiment, a compound containing tolyltriazole is selected.

The one or more metal corrosion inhibitors may be present in amounts ranging from about 0.01 wt % to about 5.0 wt %, preferably about 0.01 wt % to about 3.0 wt %, and more preferably from about 0.01 wt % to about 1.5 wt %, based on the total weight of the engine oil lubricant composition.

Seal compatibility agents

Seal compatibility agents help to swell elastomeric seals by causing a chemical reaction in the fluid or physical change in the elastomer. Suitable seal compatibility agents for lubricating oils include organic phosphates, aromatic esters, aromatic hydrocarbons, esters (butylbenzyl phthalate, for example), and polybutenyl succinic anhydride. Such additives may be used in an amount of about 0.01 to 3 wt %, preferably about 0.01 to 2 wt %, based on the total weight of the engine oil lubricant.

Anti-Foam

Anti-foam agents may advantageously be added to lubricant compositions. These agents retard the formation of stable foams. Silicones and organic polymers are typical anti-foam agents. For example, polysiloxanes, such as silicon oil or polydimethyl siloxane, provide antifoam properties. Anti-foam agents are commercially available and may be used in conventional minor amounts along with other additives such as demulsifiers; usually the amount of these additives combined is less than 1 weight percent and often less than 0.1 wt %, based on the total weight of the engine oil lubricant composition.

When lubricating oil compositions contain any one or more of the additives discussed above, the additive(s) are blended into the composition in an amount sufficient for it to perform its intended function. Illustrative amounts of such additives that can be used in the engine oil lubricants described herein are shown in Table 1 below.

Note that many of the additives are shipped from the manufacturer and used with a certain amount of base oil diluent in the formulation. Accordingly, the weight amounts in Table 1, as well as other amounts mentioned in this specification, are directed to the amount of active ingredient (that is the non-diluent portion of the ingredient). The wt % indicated below are based on the total weight of the lubricating oil composition.

TABLE 1 Typical Amounts of Various Lubricant Oil Components Approximate Approximate Compound wt % (Useful) wt % (Preferred) Detergent 0.01-6 0.01-4  Dispersant  0.1-20 0.1-8  Friction Modifier 0.01-5 0.01-1.5 Viscosity Modifier  0.1-8 0.1-6  (solid polymer basis) Antioxidant  0.1-5  0.1-2.0 Anti-wear Additive 0.01-6 0.01-4  Pour Point Depressant  0.0-5 0.01-1.5 Anti-foam Agent 0.001-3  0.001-0.15 Basestock or base oil Balance Balance

The foregoing additives may be added independently or may be pre-combined in packages which can be obtained from suppliers of lubricant oil additives. Additive packages with a variety of ingredients, proportions and characteristics are available and selection of the appropriate package will take the requisite use of the ultimate composition into account. The additive package may be incorporated into the engine oil lubricant compositions at loadings of about 9 wt % to about 15 wt %, or about 10 wt % to about 14.5 wt %, or about 11 wt % to about 14 wt %, based on the total weight of the lubricant composition.

EXAMPLES

The foregoing discussion can be further described with reference to the following non-limiting examples. Typical properties of the basestocks used in the examples are shown below in Table 2.

TABLE 2 Properties of Basestocks Used KV40, KV100, CCS-35, Pour Flash cSt cSt VI cP Point, ° C. Point, ° C. PAO 3.4 13.6 3.4 127 829 −75 227 Group IV PAO 2 5.1 1.7 89 144 −63 161 Group IV GTL 3 10.1 2.7 112 513 −39 201 Group II Yubase 3 12.3 3.1 108 1091 −33 198 Group II EHC 20 9.9 2.7 106 704 −41 188 Group II

Twelve (12) engine lubricant oil formulations were prepared and evaluated to determine the evaporation rate of the lubricant oil within a temperature range of 308° C. to 345° C. using simulated distillation method DIN 51454 mod. C17-C19. For each test, the evaporation was limited to 1.5 wt %. Viscosity was measured by HTHS 150° C. (ASTM D4683). Noack volatility (%) was measured according to ASTM D5800. Table 3 below shows the formulations for each example (Comparative Example A1 and Inventive Examples A2 to A12).

An unexpected finding was made when GTL 3 was added to the formulation examples. Examples with GTL 3 in the formulation showed the lowest evaporation rate compared to the other examples containing base stocks at the same Noack level. Usually a low evaporation rate in this test leads to a very low oil consumption in service.

TABLE 3 Oil formulations tested for evaporation rate. Comp. Example Ex. A1 A2 A3 A4 A5 A6 mPAO 3.x Group IV base stock 83.37 70.87 52.37 35.87 71.87 54.37 GTL 3 Group II base stock 11.50 29.00 44.00 Yubase 3 Group II base stock 11.00 28.00 PAO 2 Group IV base stock Additive Package 14.13 14.13 14.13 14.13 14.13 14.13 SV603 Star VM 2.50 3.50 4.50 6.00 3.00 3.50 EHC 20 Group II base stock HTHS 150, cP 1.94 1.97 1.94 1.93 1.92 1.93 Noack, % 12.0 14.8 20.9 26.5 14.2 20.0 DIN 51454 mod. C17-C19 0.3 0.6 1.2 2.8 1.8 3.3 Evaporation, % Example A7 A8 A9 A10 A11 A12 mPAO 3.x Group IV base stock 35.87 77.37 69.37 59.37 61.87 48.87 GTL 3 Group II base stock Yubase 3 Group II base stock 46.00 PAO 2 Group IV base stock 5.00 11.50 19.50 EHC 20 Group II base stock 20.00 32.00 Additive Package 14.13 14.13 14.13 14.13 14.13 14.13 SV603 Star VM 4.00 3.50 5.00 7.00 4.00 5.00 HTHS 150, cP 1.98 1.92 1.90 1.90 1.94 2.01 Noack, % 25.0 15.5 20.4 26.4 19.1 23.3 DIN 51454 mod. C17-C19 4.8 4.7 12.1 20.5 4.1 6.2 Evaporation, %

It was surprisingly and unexpectedly discovered that oil formulations having different basestock mixtures, as the major constituent, at the same Noack volatility level provided significantly different simulated oil consumption rates. For example, the inventive samples 2, 5, 8 all had greater than 70 wt % of the mPAO 3.x Group IV base stock, a viscosity of less than 2.0 cP, a Noack volatility of about 15%, but showed significantly different simulated evaporation rates (0.6, 1.8, and 4.7 respectively). FIG. 1 graphically displays these differences in evaporation rates versus Noack volatility.

To validate the findings from the above simulations, an engine oil consumption test was performed. The test cycles were consisting of customer relevant city driving and high speed sections.

Examples with GTL 3 unexpectedly showed a very low evaporation in the simulated distillation test (DIN 51454 mod.) and also performed very well in the engine test. These examples considerably exceeded the oil consumption expectation in the city cycle (4-6 gr/hr) and high speed cycle (14-16 gr/hr). FIG. 2 shows the oil consumption versus Noack volatility relationship from this engine test.

The foregoing engine oil lubricant compositions can further include any one or more of the following embodiments:

Embodiment 1. An engine oil lubricant composition comprising: about 40 wt % to about 80 wt % of a first oil base stock consisting of a Group IV base oil, and about 10 wt % to about 40 wt % of a second oil base stock that is not a Group IV base oil, where the weight percents are based on the total weight of the engine oil lubricant composition, wherein the engine oil lubricant composition has an HTHS (ASTM D4683) of less than or equal to 2.2 cP at 150° C., a Noack volatility (ASTM D5800) of 25% or less, and an evaporation rate of 6% or less as measured by distillation method DIN 51454 mod. C17-C19.

Embodiment 2. The lubricant composition of embodiment 1, wherein the HTHS (ASTM D4683) is less than or equal to 2.0 cP at 150° C.

Embodiment 3. The lubricant composition of embodiment 1 or 2, further comprising a third base oil stock comprising a Group I, Group II, Group III, Group IV or Group V base oil.

Embodiment 4. The lubricating engine oil of any embodiments 1 to 3, wherein the second oil base stock comprises a Group II base oil.

Embodiment 5. The lubricant composition of embodiments 3 or 4, wherein the Group II base stock is a Gas to-Liquids (GTL) base stock.

Embodiment 6. The lubricant composition of any embodiments 3 to 5, wherein the Group V base stock has a kinematic viscosity at 100° C. of from 2 to 6 cSt.

Embodiment 7. The lubricant composition of any embodiments 3 to 5, wherein the Group V base stock has a kinematic viscosity at 100° C. of 5 cSt or less.

Embodiment 8. The lubricant composition of any of embodiments 1 to 7, further comprising one or more anti-wear additives, other viscosity modifiers, antioxidants, detergents, other dispersants, pour point depressants, corrosion inhibitors, metal deactivators, seal compatibility additives, anti-foam agents, inhibitors, anti-rust additives, or any one or more combinations thereof.

Embodiment 9. An engine oil lubricant composition comprising: about 40 wt % to about 80 wt % of a first oil base stock consisting of a Group IV base oil, and about 10 wt % to about 40 wt % of a second oil base stock comprising a Group II base oil, where the weight percents are based on the total weight of the engine oil lubricant composition, wherein the engine oil lubricant composition has an HTHS (ASTM D4683) of less than or equal to 2.2 cP at 150° C., a Noack volatility (ASTM D5800) of 25% or less, and an evaporation rate of 6% or less as measured by distillation method DIN 51454 mod. C17-C19.

Embodiment 10. The lubricant composition of embodiment 9, wherein the HTHS (ASTM D4683) is less than or equal to 2.0 cP at 150° C.

Embodiment 11. The lubricant composition of embodiment 9 or 10, further comprising a third base oil stock comprising a Group I, Group III, or Group V base oil.

Embodiment 12. The lubricant composition of any embodiments 9 to 11, further comprising a third base oil stock comprising a Group V base stock that has a kinematic viscosity at 100° C. of from 2 to 6 cSt.

Embodiment 13. The lubricant composition of any embodiments 9 to 11, further comprising a third base oil stock comprising a Group V base stock that has a kinematic viscosity at 100° C. of 5 cSt or less.

Embodiment 14. The lubricant composition of any embodiments 9 to 13, further comprising one or more anti-wear additives, other viscosity modifiers, antioxidants, detergents, other dispersants, pour point depressants, corrosion inhibitors, metal deactivators, seal compatibility additives, anti-foam agents, inhibitors, anti-rust additives, or any one or more combinations thereof.

Embodiment 15. The lubricant composition of any embodiments 9 to 14, wherein the Group II base stock is a Gas to-Liquids (GTL) base stock.

Embodiment 16. An engine oil lubricant composition comprising: about 40 wt % to about 80 wt % of a first oil base stock consisting of a Group IV base oil, about 10 wt % to about 40 wt % of a second oil base stock comprising a Group II base oil, where the weight percents are based on the total weight of the engine oil lubricant composition, and at least 5 wt % of a third base oil stock comprising a Group V base stock that has a kinematic viscosity at 100° C. of from 2 to 6 cSt, wherein the engine oil lubricant composition has an HTHS (ASTM D4683) of less than or equal to 2.2 cP at 150° C., a Noack volatility (ASTM D5800) of 25% or less, and an evaporation rate of 6% or less as measured by distillation method DIN 51454 mod. C17-C19.

Embodiment 17. The lubricant composition of embodiment 16, wherein the third base oil stock comprising the Group V base stock has a kinematic viscosity at 100° C. of 2 to 5 cSt.

Embodiment 18. The lubricant composition of embodiment 16 or 17, wherein the HTHS (ASTM D4683) is less than or equal to 2.0 cP at 150° C.

Embodiment 19. The lubricant composition of any embodiment 16 to 18, wherein the Group II base stock is a Gas to-Liquids (GTL) base stock.

Embodiment 20. The lubricant composition of any embodiments 16 to 19, further comprising one or more anti-wear additives, other viscosity modifiers, antioxidants, detergents, other dispersants, pour point depressants, corrosion inhibitors, metal deactivators, seal compatibility additives, anti-foam agents, inhibitors, anti-rust additives, or any one or more combinations thereof.

It will thus be seen that the objects set forth above, among those apparent in the preceding description, are efficiently attained and, since certain changes may be made in carrying out the present invention without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawing be interpreted as illustrative and not in a limiting sense.

Applicants have attempted to disclose all embodiments and applications of the disclosed subject matter that could be reasonably foreseen. However, there may be unforeseeable, insubstantial modifications that remain as equivalents. While the present disclosure has been described in conjunction with specific, exemplary embodiments thereof, it is evident that many alterations, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description without departing from the spirit or scope of the present disclosure. Accordingly, the present disclosure is intended to embrace all such alterations, modifications, and variations of the above detailed description.

All patents, test procedures, and other documents cited herein, including priority documents, are fully incorporated by reference to the extent such disclosure is not inconsistent with this disclosure and for all jurisdictions in which such incorporation is permitted.

Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges including the combination of any two values, e.g., the combination of any lower value with any upper value, the combination of any two lower values, and/or the combination of any two upper values are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are “about” or “approximately” the indicated value, meaning the values take into account experimental error, machine tolerances and other variations that would be expected by a person having ordinary skill in the art.

It is also understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention, which as a matter of language, might be said to fall there between. 

1. An engine oil lubricant composition comprising: about 40 wt % to about 80 wt % of a first oil base stock consisting of a Group IV base oil, and about 10 wt % to about 40 wt % of a second oil base stock that is not a Group IV base oil, where the weight percents are based on the total weight of the engine oil lubricant composition, wherein the engine oil lubricant composition has an HTHS (ASTM D4683) of less than or equal to 2.2 cP at 150° C., a Noack volatility (ASTM D5800) of 25% or less, and an evaporation rate of 6% or less as measured by distillation method DIN 51454 mod. C17-C19.
 2. The lubricant composition of claim 1, wherein the HTHS (ASTM D4683) is less than or equal to 2.0 cP at 150° C.
 3. The lubricant composition of claim 1, further comprising a third base oil stock comprising a Group I, Group II, Group III, Group IV or Group V base oil.
 4. The lubricating engine oil of claim 1, wherein the second oil base stock comprises a Group II base oil.
 5. The lubricant composition of claim 3, wherein the Group II base stock is a Gas to-Liquids (GTL) base stock.
 6. The lubricant composition of claim 3, wherein the Group V base stock has a kinematic viscosity at 100° C. of from 2 to 6 cSt.
 7. The lubricant composition of claim 3, wherein the Group V base stock has a kinematic viscosity at 100° C. of 5 cSt or less.
 8. The lubricant composition of claim 1, further comprising one or more anti-wear additives, other viscosity modifiers, antioxidants, detergents, other dispersants, pour point depressants, corrosion inhibitors, metal deactivators, seal compatibility additives, anti-foam agents, inhibitors, anti-rust additives, or any one or more combinations thereof.
 9. An engine oil lubricant composition comprising: about 40 wt % to about 80 wt % of a first oil base stock consisting of a Group IV base oil, and about 10 wt % to about 40 wt % of a second oil base stock comprising a Group II base oil, where the weight percents are based on the total weight of the engine oil lubricant composition, wherein the engine oil lubricant composition has an HTHS (ASTM D4683) of less than or equal to 2.2 cP at 150° C., a Noack volatility (ASTM D5800) of 25% or less, and an evaporation rate of 6% or less as measured by distillation method DIN 51454 mod. C17-C19.
 10. The lubricant composition of claim 9, wherein the HTHS (ASTM D4683) is less than or equal to 2.0 cP at 150° C.
 11. The lubricant composition of claim 9, further comprising a third base oil stock comprising a Group I, Group III, or Group V base oil.
 12. The lubricant composition of claim 9, further comprising a third base oil stock comprising a Group V base stock that has a kinematic viscosity at 100° C. of from 2 to 6 cSt.
 13. The lubricant composition of claim 9, further comprising a third base oil stock comprising a Group V base stock that has a kinematic viscosity at 100° C. of 5 cSt or less.
 14. The lubricant composition of claim 9, further comprising one or more anti-wear additives, other viscosity modifiers, antioxidants, detergents, other dispersants, pour point depressants, corrosion inhibitors, metal deactivators, seal compatibility additives, anti-foam agents, inhibitors, anti-rust additives, or any one or more combinations thereof.
 15. The lubricant composition of claim 9, wherein the Group II base stock is a Gas to-Liquids (GTL) base stock.
 16. An engine oil lubricant composition comprising: about 40 wt % to about 80 wt % of a first oil base stock consisting of a Group IV base oil, about 10 wt % to about 40 wt % of a second oil base stock comprising a Group II base oil, where the weight percents are based on the total weight of the engine oil lubricant composition, and at least 5 wt % of a third base oil stock comprising a Group V base stock that has a kinematic viscosity at 100° C. of from 2 to 6 cSt, wherein the engine oil lubricant composition has an HTHS (ASTM D4683) of less than or equal to 2.2 cP at 150° C., a Noack volatility (ASTM D5800) of 25% or less, and an evaporation rate of 6% or less as measured by distillation method DIN 51454 mod. C17-C19.
 17. The lubricant composition of claim 16, wherein the third base oil stock comprising the Group V base stock has a kinematic viscosity at 100° C. of 2 to 5 cSt.
 18. The lubricant composition of claim 16, wherein the HTHS (ASTM D4683) is less than or equal to 2.0 cP at 150° C.
 19. The lubricant composition of claim 16, wherein the Group II base stock is a Gas to-Liquids (GTL) base stock.
 20. The lubricant composition of claim 16, further comprising one or more anti-wear additives, other viscosity modifiers, antioxidants, detergents, other dispersants, pour point depressants, corrosion inhibitors, metal deactivators, seal compatibility additives, anti-foam agents, inhibitors, anti-rust additives, or any one or more combinations thereof. 